B&R upgrades modular shuttle transport for higher load handling

Modular shuttle transport systems are increasingly used in high-speed automation lines where throughput depends on precise motion control and compact layout design. B&R has introduced a Metal-to-Metal (M2M) upgrade for ACOPOStrak to increase load capacity, improve curve performance, and reduce mechanical wear.

Why higher loads change the mechanical requirements
When shuttles carry heavier or overhanging loads, mechanical forces rise sharply—especially during high acceleration and high-speed motion. In these cases, guide and shuttle interfaces face higher stress levels, which can affect positioning accuracy, curve stability, and long-term wear.

This is particularly relevant in assembly automation, where components must be positioned quickly and repeatably, and in packaged consumer goods (CPG) production where transport layouts are designed to maximise throughput per square metre.

Metal-to-Metal upgrade targets curve speed, acceleration, and wear
The Metal-to-Metal (M2M) upgrade is designed to change the mechanical interface between the shuttle and guide system, shifting to a metal-based guide and shuttle configuration. The stated intent is to improve how the system handles higher forces and dynamics, especially during curve motion.

B&R links this to three practical outcomes in high-duty transport applications: the ability to handle heavier loads, operate through curves at higher speeds and acceleration, and reduce wear at the shuttle-guide interface, lowering maintenance requirements and improving operational availability.

Compact curve design for higher shuttle density
A key part of the upgrade is its combination with a compact curve design intended to increase shuttle density on the track. B&R states that the configuration enables transport of a virtually unlimited number of shuttles with no spacing gaps, with each shuttle handling loads of up to 10 kg at speeds of up to 5 m/s.

For high-volume environments, the technical relevance is tied to layout efficiency: tighter curves and higher shuttle density can increase throughput per unit area, which is a central design constraint in CPG lines and in other space-limited automation cells.

Where the upgrade fits in industrial automation
With the Metal-to-Metal upgrade, ACOPOStrak is positioned for applications where payload weight, shuttle dynamics, and reliability are limiting factors. By increasing the system’s tolerance for high forces from heavy or overhanging loads, the upgrade targets faster transport cycles while maintaining precision in demanding operating environments.

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